Ultrasonic Horns and Boosters

Ultrasonic horns and ultrasonic boosters are used with ultrasonic transducers and converters. Boosters or velocity transformers amplify ultrasonic vibrations. Ultrasonic horns, sontrodes, anvils, blades or probes contact and transmit ultrasonic vibration.

Ultrasonic tools or tooling such as ultrasonic resonators, ultrasonic anvils, ultrasonic blades, ultrasonic knifes, ultrasonic tips, ultrasonic concentrators, ultrasonic amplifiers, or ultrasonic boosters alter, couple, or transfer the signals produced by ultrasonic transducers or ultrasonic converters to the workpiece or liquid.

Ultrasonic boosters, amplifiers, concentrators, or velocity transformers increase the amplitude of the ultrasonic vibrations emitted by the ultrasonic converter or transducer, and then transmit these amplified vibrations to the horn or resonator. Horns, anvils, blade, resonators and tips contact the parts or fluid being processed. The horns or sonotrode are attached to the boosters, which are then attached to the transducer or converter. The horn-booster-converter forms an ultrasonic head or stack. Some stacks can consist of several daughter horns or sonotrodes mounted on a mother booster.

The ultrasonic booster adjusts the vibrational output from the transducer and transfers the ultrasonic energy to the horn. The booster also generally provides a method for mounting the ultrasonic stack to a support structure. The ultrasonic horn then contacts and delivers power to the load.

The horn's shape depends on the shape of the load and the required gain. Different styles of ultrasonic horns include bell-shaped, bar, catenoidal cutting horns, composite ultrasonic horns, exponential horns, inserting horns, round ultrasonic horns, and tuned bolt style. Other, unlisted styles of ultrasonic horns may also be available.

Horns are typically made of titanium, aluminum, and steel. Coating options are commonly available for ultrasonic horns as well; typical offerings include chrome plating, anodized coatings, and carbide spray. Other coating options may also be available for ultrasonic horns.

Applications for ultrasonic horns and boosters include abrasive machining, atomizing, bonding, cleaning, crystallization, cutting, defoaming, die bonding, fluid processing, homogenization, joining, mixing, packaging sealing, plastic welding, riveting, sealing, seaming, spot welding, surface treatment, wire bonding, non-destructive testing, and more

• How Ultrasonic Welding Works
  Ultrasonic assembly utilizes an acoustic tool called a horn to transfer vibratory energy through the part to the joint area, where it is converted to heat through friction that melts the plastic....
  (read more)

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